Mesostructured Zeolitic Materials, and Methods of Making and Using the Same

Abstract

One aspect of the present invention relates to mesostructured zeolites. The invention also relates to a method of preparing mesostructured zeolites, as well as using them as cracking catalysts for organic compounds and degradation catalysts for polymers.

Description

RELATED APPLICATIONS [0001] This application claims the benefit of and priority to U.S. patent application Ser. No. 10 / 830,714, filed on Apr. 23, 2004, and entitled “Mesostructured Zeolitic Materials, and Methods of Making and Using the Same.” This application also claims benefit and priority to the PCT application entitled “Mesostructured Zeolitic Materials, and Methods of Making and Using the Same,” International patent application serial No. PCT / US05 / 14129, filed on Apr. 22, 2005.GOVERNMENT FUNDING [0002] This invention was made with support under Grant Number DAAD19-02-D0002, awarded by the Army Research Office; the government, therefore, has certain rights in the invention.BACKGROUND OF THE INVENTION [0003] Zeolites and related crystalline molecular sieves are widely used due to their regular microporous structure, strong acidity, and ion-exchange capability. van Bekkum, H., Flanigen, E. M., Jacobs, P. A., Jansen, J. C. (editors), Introduction to Zeolite Science and Practice, 2...

AI Technical Summary

Benefits of technology

[0026] In another aspect, the present invention relates to a method of refining crude oil comprising contacting the crude oil with a mesostructured zeolite. In a further embodiment, the contacting of the oil with the mesostructured zeolite takes place within a Fluid Catalytic Cracking Unit. In a further embodiment, production of gasoline is increased relative to the amount of gasoline produced in the absence of the mesostructured zeolite. In a further embodiment, production of light olefins is increased relative to the amount of light olefins produced in the absence of the mesostructured zeolite.

[0081] Moreover, the inorganic material of the additive can have a chemical composition framework that is substantially the same as a chemical composition framework of the inorganic material before the plurality of mesopores were defined (e.g., formed or created) within the inorganic material. The inorganic material can also have a connectivity that is substantially the same as the connectivity of the inorganic material prior to defining (e.g., forming or creating) the plurality of mesopores within the inorganic material. In some embodiments, the inorganic material of the additive has an improved intracrystalline diffusion compared to the intracrystalline diffusion of the inorganic material prior to defining the plurality of mesopores within the inorganic material.

[0102] Another aspect of the invention features an inorganic material including a fully crystalline mesostructure comprising mesopore surfaces defining a plurality of mesopores, such that a cross-sectional area of each of the plurality of mesopores is substantially the same, and a binder formed into a shape. The shape can include a monolith, a pellet, a bead, a powder, and / or a spray. The binder can include aluminum oxide, silicon oxide, amorphous aluminosilicate, clay, titania, zirconia, and / or cellulose. An additive material can be included to enhance at least one of sulfur tolerance (e.g., sour feedstocks), metal tolerance (e.g., impurities or contaminants present in a feedstock), catalytic activity, catalyst life, and / or hydrothermal stability. The additive material can include alumina, silica, calcium oxide, magnesium oxide, antimony passivators, nanosized zeolites, and / or ZSM-5 zeolite.

[0103] Yet another aspect of the invention features an inorganic material comprising a crystalline nanostructure comprising a plurality of members, each member defining a plurality of pores, and adjacent members defining voids therebetween. At least one dimension of each of the plurality of members is less than 100 nm. Also included is a binder formed into a shape. The shape can include a monolith, a pellet, a bead, a powder, and / or a spray. The binder can include aluminum oxide, silicon oxide, amorphous aluminosilicate, clay, titania, zirconia, and / or cellulose. An additive material can be included to enhance sulfur tolerance, metal tolerance, catalytic activity, catalyst lifetime, and / or hydrothermal stability of the inorganic material.

Problems solved by technology

However, their applications are limited by their small pore openings, which are typically narrower than 1 nm.

However, unlike zeolites, MCM-41-type materials are not crystalline, and do not possess strong acidity, high hydrothermal stability and high ion-exchange capability, which are important for certain catalytic applications.

However, due to the lack of long-range crystallinity in these materials, their acidity was not as strong as those exhibited by zeolites.

Previous attempts to prepare mesostructured zeolitic materials have been ineffective, resulting in separate zeolitic and amorphous mesoporous phases.

Moreover, some authors pointed out the difficulty of synthesizing thin-walled mesoporous materials, such as MCM-41, with zeolitic structure, due to the surface tension associated with the high curvature of the mesostructure.

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